Rotary Kiln Shells Welding

Craftwork Procedure

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 一、Overview
印尼 BAYAH10000t/d 熟料水泥生产线，Ф6.2×92m 回转窑焊接工序是设备安装
中最重要的环节之一；筒体组对，焊缝焊接的质量好坏，将直接影响其能否正常运行
和使用寿命。为确保窑体焊接质量，特制定此筒体焊接施工艺流程。
The Ф6.2×92m rotary kiln shells welding is one of the key links
of equipment installations for Indonesia BAYAH 10000t/d clinker& cement
production plant. Its shells assembly and welding joints quality will
directly affect its normal operation and service time. This kiln shells
welding procedure is specified drawn up for insurance of welding
quality.
二、焊接前的准备工作：Preparations prior to starting welding
1、窑筒体的焊接——手工直流弧焊法；
Manuel DC arc welding method is applied for kiln shells welding.
2、窑筒体焊接工作预计 50 天；
The estimated weld duration is 50 days.
3） 编制窑筒体对接焊接工艺流程；
Drawing up rotary kiln shells joints welding craftwork procedures.
4） 窑筒体焊接工作，必须在窑筒体找正合格后进行，并可利用临时固定 的
传动装置转窑施焊；
The welding of the kiln shell could only be carried out after the
alignment of the kiln shell is checked up and use the drive unit fixed
temporarily for kiln barring when welding the kiln.

5） 焊接前对焊工必须进行考试，考试内容应每人焊接一焊块试，通过探伤检
查，全部合格者，才允许参加窑筒体焊接工作；
All welders must be through sample piece welding examination, only
UT qualified ones can participate kiln shells joints welding.
6） 窑筒体焊接所用焊条应符合 GB5117 和 GB5118 的有关规定，其质量应保 证
焊缝的力学性能不低于母材力学性能；
The welding rods for welding the kiln shell should accord with
the relevant stipulations of GB5117 and GB5118 and the mechanical
performance should not be lower than that of the kiln shell.
7） 焊条在使用前必须进行烘干，温度为 250～300℃，烘干时间为 1 小 时，
烘干后降温至 150℃左右恒温保存，随用随取，避免在空气中停留较长时间；
Dry the electrodes before use with temperature of 250～300℃ and
dry time of one hour. After dry, reduce the temperature to about
150℃ to conserve in a constant temperature and take them when
necessary to avoid longer retained time in the air.
8） 焊接前对窑筒体的坡口形式，尺寸应进行检查，坡口处不得有分层、
裂纹、夹渣等影响质量的缺陷。坡口形式为双面双边坡口（详见图样）。坡口 形
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 式及有关尺寸示例见图 2-3。如果要采用自动焊接，则应核对坡口形式和尺 寸，
并做相应修改。
Check the type and dimension of the groove before welding.
Defects influencing quality such as delamination, crack and residue,
etc are not allowed. The groove should be of double groove as shown
in the drawing. Refer to drawing 2-3 for demonstration of
type and the relevant dimension of groove. Check the type and
dimension of the groove and do the corresponding revision if
automatic welding is adopted.

三、窑筒体焊接人员及材料工具组织 Welder & Machinery Mobilization

工种配备表 Specialties & Machinery list

Supervisor Welder Technician Electrician Safety Helper

2 5 1 1 1 2

手工焊施工主要工机具一览表 Manual Welding Main Machinery list

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SN. Name Specification Unit Quantity

1 DC Arc weld machine DC-630A Unit 5

2 dry oven 100kg Unit 1

3 Air compressor 1M13H Unit 2

4 axial fan 2.2KW Unit 1

5 polisher Ф125 ㎜ Unit 8

6 air gouging piece 2

7 insulation barrel set 6

8 welding wire 70 ㎡ meter 360

Weld joint
9 bottle 40
penetration

10 weld clamp 500A piece 10

11 hand hammer piece 9

12 flat shovel piece 9

13 wire brush Ф125 ㎜ piece 20

14 brush piece 9

四 、窑筒体焊接
Welding of the kiln shell
1) 窑筒体坡口必须保证高度清洁和干燥，应在焊接前用钢丝刷严格清 刷，
直到露出金属光泽为止。
The groove of the kiln shell must be kept absolutely clean and
dry. Clean the groove with a steel brush before welding till the
metal brightness appears.
2） 雨天或刮风时不应进行焊接工作。如在雨季进行焊接，必须在 每道需
焊的焊缝上搭一遮蓬，以防焊接进行中突然下雨，淋湿焊缝。遇此情 况，可将手
头的那道焊缝焊完后停止工作，待雨停后再进行，此时应注意保证 焊缝干燥。
Welding should not be carried out when it is raining . A canopy
must be put up on each welding seam needed to be welded to avoid
being caught in the sudden rain during welding if the welding is
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carried out in rainy season. Stop welding after the welding on hand
is finished and go on the welding after the rain stops if this
condition is met and pay attention to ensure the welding seam dry at
this time.
3） 焊接工作应在安全和良好的劳动条件下进行，电焊机不得放在窑筒
体内，不得把电焊机的地线接在轮带或托轮上，电缆线要有可靠的绝缘措施，
焊接地点要有良好的低压照明、通风和保温，以及可以顺利操作的工作台和蔽
棚等。此外，还要在焊接工人与操纵盘窑传动人员之间建立通讯联系。
The welding must be carried out in good and safe working
conditions. The welding machine should never be put inside the kiln
shell and the zero line should not be connected to the tyre or
supporting rollers. The electric cable must be well insulated. The
welding site must be kept warm and have good lighting and
ventilation, an easy-to –handle operation platform and shield place.
Besides, the communication facilities must be set up between the
welder and the worker who is barring the kiln.

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 4） 接口焊接 Welding at the joints
a） 为了减小焊接变形，可采取一道焊缝两人对称同时操作；
Two people symmetrically welding the same welding seam at the
same time might be adopted in order to reduce the welding
deformation.
b） 焊接要根据窑筒体中心线测量结果编排好每道焊缝的施焊程序及各道 焊
缝的起弧点位置。在施焊时，要把最大弯曲点转到最高点，利用窑筒体本身 的重
量纠正窑筒体的中心线弯曲度；
Determine the welding procedure and the beginning point of each
welding seam according to measuring results of the kiln shell
centerline when welding. Switch the maximum bending point to the
highest point when welding and correct the bend of the kiln shell
centerline under the weight of the kiln itself.
c） 施焊工作应先焊接靠近大齿圈处的焊缝，以减小对大齿圈处的焊接变 形
影响；
First do the welding near the girth gear to reduce the influence on
the girth gear when welding.

d） 潮湿地区，焊接时务必采用火焰枪，将接口处的水气烤干，以免焊缝 内形成气孔；
Flame gun must be used to parch the hydrosphere at the joints to avoid
air vent forming in the welding seam when welding in wet area.

e） 为保证焊接质量，每焊完一层须用小尖锤敲击焊缝，失放焊接应力，
并用钢丝刷清除药皮、焊渣、焊瘤等，然后用砂轮清除坡口两侧夹缝以保证光 滑
无夹渣，最后用钢刷清除焊缝内杂物；
When the welding of one layer is finished, a small sharp hammer must
be used to knock the welding seam to release welding stress to ensure
the welding quality and remove the medical

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skin, welding residue and welding hump, etc with steel brush, then
remove the crack of the two sides of the groove with grinding wheel to
ensure smooth, and at last remove the sundries in the welding seam
with steel brush.

f） 每焊完一层，检测一次窑筒体的中心线，根据测量结果，决定下一次 的
起焊点，但每层的起弧位置要错开 50mm 以上；
Check the kiln centerline once after welding of one layer is finished.
Determine the beginning point of the next welding according the
measuring results and the beginning point of welding of each layer
must stagger above 50 mm.

g） 焊缝处拉紧螺栓，调整块等件，在焊缝达到足够强度后，才能割除， 筒
体内支撑在全部焊接完毕，并经窑筒体中心线测量合格后方可割除。上述物 件的
割除不允许使用电弧切割，以免损伤窑筒体，可采用火焰切割。
Tense bolts and adjusting blocks at the welding seam could only be
removed when the welding seam reaches the intensity. Support in the
shell could only be removed when all the welding is finished and the
measuring of the kiln shell centerline is accepted. It is not
allowed to use arc to incise the above things to prevent the kiln
shell from damaging and flame cutting might be applied.

五 窑筒体焊接质量检查 Welding quality inspection of the kiln shell

1 ） 焊缝外观检查

Outward appearance inspection of welding

seam

a） 焊缝表面应呈平滑细鳞的形状，接点处无凹凸现象；
The welding seam surface should be smooth and it is not
accidented at the joints.
b） 焊缝表面及热影响区域不得有裂纹；
It is not allowed that the cracks exists at the welding seam
surface and the area affected by heat.

c） 焊缝咬边深度不得大于 0.5mm，咬边连续长度不得大于 100mm，焊缝咬

边总长度不得大于该焊缝长度的 10%；
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 d） The biting side depth of welding seam should not be above 0.5
mm with continuous length of biting side not above 100 mm and
the total length of biting side of welding seam not above 10%
of the length of this welding seam.

d） 焊缝高度 窑筒体外部不得大于 3mm，窑筒体内部烧成带区域不得大于

0.5mm（即从热端算起八倍窑筒体内直径的范围内），其它区段不得大于
1.5mm。焊缝的最低 点不得低于窑筒体表面并应饱满。
The height of welding seam at the outside of the kiln shell should not
be above 3 mm, at the burning zone not above 0.5 mm (that is within
eight times of the kiln shell diameter from the hot end) and at the
other area not above 1.5 mm. The lowest point of welding seam should
not be lower than the kiln shell surface and should be full.

2） 焊缝的探伤检查 Flaw detection of welding seam

a） 探伤人员必须持资质证书或考试合格证；
Person of flaw detection must have quality
certificate or test certificate.

b） 当采用超声波探伤时，每条焊缝均应检查，探伤长度不小于该条焊缝 的
25%。焊缝交叉处必须全部检查。质量评定达到 GB11345 中的Ⅱ级为合格。
UT shall account for 25% of total welding joints and shall be
applied for each joint especially for all cross joints. The qualified
joints shall reach the Second Degree of GB11345 for UT.
c） 焊缝不合格时，应对该条焊缝加倍长度检查，若再不合格时，则对其 焊
缝做 100%检查；
The double length of this welding seam should be inspected if the
welding seam could not

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meet the requirements. If the welding seam still can’t reach the
requirements the 100% inspection of welding seam should be carried
out.

d） 焊缝的任何部位返修次数不得超过两次，超过两次须由技术总负责人

批准，并且返修部位和次数应在产品质量证明书中说明。

Repair times of welding seam at any place should not be over twice.
If the times are over twice, it must be approved by the technical
general principal and the repair positions and times must be
illustrated in the product quality instructions.

3） 筒体焊接后，如下图所示，长度和轮带间距公差应符合下列规定：

When the kiln shell has been welded, it is shown in the following
drawing. The tolerance of the length and tyre distance should accord
with the following stipulations.

相邻两轮带中心距L1的Δ1=0.025%L1；

b） 任意两轮带中心距L2的Δ2=0.02%L2；

c） 首尾轮带中心到窑端面距离L3的Δ3=0.03%L3；

d） 全长L的Δ=0.025%L。 符合要求后，按1.4、1.5、1.6的要求将轮带最终
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定位，并焊上轮带两侧的挡环。 应当指出，在焊接过程中应注意防止杂物和焊渣
掉入轮带与垫板之间及轮带和托轮表面上。在轮带周围施工焊后必须立即用压缩
空气吹净。 当上述各项工作都完成后应进行一次复查工作，作出记录，作为交工
验收的文件之一。

a) The deflection of center distance L1 of the two neighboring tyres

Δ1=0.025%L1.

b) The deflection of center distance L2 of two random tyres

Δ2=0.02%L2.

c) The deflection of distance L3 from the center of the

first and last tyre to the kiln end

Δ3=0.03%L3.

d) The deflection of the whole length L Δ=0.025%L.

The final position of the tyres should be carried out according to

the requirements of 1.4, 1.5 and 1.6 after having met the
requirements and weld the thrust rings of the both sides of the tyre.

It should be pointed out that measures should be taken to prevent

foreign object or welding residue from getting into the space
between the tyre and space pads. Compressed air must be used to blow
immediately after welding when the construction is carried out
around the tyre. After all the above mentioned work has been
finished, the overall re-inspection must be carried out, records
will be taken and used as one of the documents for completion
acceptance.

六、焊接安全生产注意事项

welding safety caution issues

1）在窑体顶部焊接外部焊口时，高空作业应十分注意， 必须拉好生命线，施工
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人员及检查人员系好安全带，防止脚下滑脱，谨防冒险蛮干。

Working at height external welding on top of kiln shell shall

particularly pay attention to safety. Life line must be set up with
inspection of safety belt by each welder and inspector. Caution of
slippery , rough working is forbidden .

2）、转窑由专人负责，转窑时应发出信号。确认后才可转动。

Rotation the kiln shells shall have dedicated worker with clear
signal warning and confirmation before staring,

3）、在焊接筒体时窑内不得进行任何其它工作。

Any other kind of working is forbidden inside the kiln shells when
welding rotary kiln.

4）、筒体内焊接应注意通风、防尘、漏电触电。内部照明应用24V安全电源。

Ventilation, dedusting, electric leakage, and electric shock shall

be noted. The power supply internal the kiln shall 24 V.

5）、电源供给点保护设备配备齐全、专人看管。

Electric power source shall equipped with protection device and with
dedicated PIC.

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